Suzuki GW250 User manual

K Dic128

GW250 L3 99500-32170-01E Cover14 (18 mm) 2012.06.12

Printed in Japan

L3

SERVICE MANUAL

G

W250

GW250

9 9 5 0 0 - 3 2 1 7 0 - 0 1 E

CHANGZHOU HAOJUE SUZUKI MOTORCYCLE CO.,LTD.

GROUP INDEX

GENERAL INFORMATION

1

PERIODIC MAINTENANCE

2

ENGINE

3

FI SYSTEM DIAGNOSIS

4

FUEL SYSTEM AND THROTTLE

BODY

5

EXHAUST SYSTEM

6

COOLING AND LUBRICATION

SYSTEM

7

CHASSIS

8

ELECTRICAL SYSTEM

9

SERVICING INFORMATION

10

EMISSION CONTROL

INFORMATION

11

WIRING DIAGRAM

12

FOREWORD

This manual contains an introductory description on

the SUZUKI GW250 and procedures for its inspec-

tion/service and overhaul of its main components.

Other information considered as generally known is

not included.

Read the GENERAL INFORMATION section to

familiarize yourself with the motorcycle and its main-

tenance. Use this section as well as other sections

to use as a guide for proper inspection and service.

This manual will help you know the motorcycle bet-

ter so that you can assure your customers of fast

and reliable service.



* This manual has been prepared on the basis

of the latest specifications at the time of publi-

cation. If modifications have been made since

then, differences may exist between the con-

tent of this manual and the actual motorcycle.

* Illustrations in this manual are used to show

the basic principles of operation and work

procedures. They may not represent the

actual motorcycle exactly in detail.

* This manual is written for persons who have

enough knowledge, skills and tools, including

special tools, for servicing SUZUKI motorcy-

cles. If you do not have the proper knowledge

and tools, ask your authorized SUZUKI

motorcycle dealer to help you.

Inexperienced mechanics or mechanics

without the proper tools and equipment

may not be able to properly perform the

services described in this manual.

Improper repair may result in injury to the

mechanic and may render the motorcycle

unsafe for the rider and passenger.

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE LOOKING FOR:

1. The text of this manual is divided into sections.

2. The section titles are listed in the GROUP INDEX.

3. Holding the manual as shown at the right will allow you to find

the first page of the section easily.

4. The contents are listed on the first page of each section to

help you find the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit, is its exploded view. Work instructions and other service information

such as the tightening torque, lubricating points and locking agent points, are provided.

Example: Front wheel

1 Brake disc

2 Collar

3 Dust seal

4 Bearing

5 Spacer

6 Front wheel

A Front axle

B Brake disc bolt



ITEM N·m

kgf-m

lbf-ft

A 18 1.8 13.0

B 65 6.5 47.0

FWD

SYMBOL MARKS AND MATERIALS

Listed in the table below are the symbols indicating instructions and other information. The meaning of each

symbol is also included in the table.

SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required.

Data beside it indicates specified

torque.

Use SUZUKI SUPER LONG LIFE

COOLANT (BLUE).

99000-99032-20X

Use SUZUKI LONG LIFE COOLANT

(GREEN) or equivalent.

99000-99032-12X

Apply oil. Use engine oil or transmis-

sion oil unless otherwise specified.

Use SUZUKI FORK OIL G10

or equivalent.

99000-99001-G10

Apply molybdenum oil solution.

(Mixture of engine oil and SUZUKI

MOLY PASTE in a ratio of 1:1)

Apply or use brake fluid.

Apply SUZUKI SUPER GREASE “A”

or equivalent.

99000-25010

Measure in voltage range.

Apply SUZUKI SILICONE GREASE

or equivalent.

99000-25100

Measure in current range.

Apply SUZUKI MOLY PASTE

or equivalent.

99000-25140

Measure in resistance range.

Apply SUZUKI BOND “1207B”

or equivalent.

99000-31140

Measure in diode test range.

Apply THREAD LOCK CEMENT

SUPER “1303” or equivalent.

99000-32030

Measure in continuity test range.

Apply THREAD LOCK CEMENT

SUPER “1322” or equivalent.

99000-32110

Use special tool.

Apply THREAD LOCK CEMENT

SUPER “1360” or equivalent.

99000-32130

Indication of service data.

Apply THREAD LOCK CEMENT

SUPER“1342” or equivalent.

99000-32050

ABBREVIATIONS USED IN THIS

MANUAL

A

ABDC : After Bottom Dead Center

AC : Alternating Current

ACL : Air Cleaner, Air Cleaner Box

API : American Petroleum Institute

ATDC : After Top Dead Center

A/F : Air Fuel Mixture

B

BBDC : Before Bottom Dead Center

BTDC : Before Top Dead Center

B+ : Battery Positive Voltage

C

CKP Sensor : Crankshaft Position Sensor

(CKPS)

CKT : Circuit

CLP Switch : Clutch Lever Position Switch

(Clutch Switch)

CO : Carbon Monoxide

CPU : Central Processing Unit

D

DC : Direct Current

DRL : Daytime Running Light

DTC : Diagnostic Trouble Code

E

ECM : Engine Control Module

Engine Control Unit (ECU)

(FI Control Unit)

ECT Sensor : Engine Coolant Temperature

Sensor (ECTS), Water Temp.

Sensor (WTS)

F

FI : Fuel Injection, Fuel Injector

FP : Fuel Pump

FPR : Fuel Pressure Regulator

FP Relay : Fuel Pump Relay

FWD : Forward

G

GEN : Generator

GND : Ground

GP Switch : Gear Position Switch

H

HC : Hydrocarbons

HO2 Sensor : Heated Oxygen Sensor (HO2S)

I

IAP Sensor : Intake Air Pressure Sensor (IAPS)

(MAP Sensor)

IAT Sensor : Intake Air Temperature Sensor

(IATS)

IG : Ignition

ISC Valve : Idle Speed Control Valve (ISCV)

J

JASO : Japanese Automobile

Standards Organization

L

LCD : Liquid Crystal Display

LED : Light Emitting Diode

(Malfunction Indicator Lamp)

LH : Left Hand

M

MAL-Code : Malfunction Code

(Diagnostic Code)

Max : Maximum

MIL : Malfunction Indicator Lamp

(LED)

Min : Minimum

N

NOX : Nitrogen Oxides

O

OHC : Over Head Camshaft

OPS : Oil Pressure Switch

P

PAIR : Pulsed Secondary Air Injection

PCM : Power control module

PCV : Positive Crankcase

Ventilation (Crankcase Breather)

R

RH : Right Hand

ROM : Read Only Memory

S

SAE : Society of Automotive Engineers

SDS : Suzuki Diagnosis System

T

TO Sensor : Tip-Over Sensor (TOS)

TP Sensor : Throttle Position Sensor (TPS)

WIRE COLOR

B : Black Gr : Gray R : Red

Bl : Blue Lbl : Light blue V : Violet

Br : Brown Lg : Light green W : White

Dg : Dark green O : Orange Y : Yellow

G : Green P : Pink

B/Bl : Black with Blue tracer O/BI : Orange with Blue tracer

B/Br : Black with Brown tracer O/R : Orange with Red tracer

B/G : Black with Green tracer O/W : Orange with White tracer

B/R : Black with Red tracer O/Y : Orange with Yellow tracer

B/W : Black with White tracer R/B : Red with Black tracer

B/Y : Black with Yellow tracer R/Y : Red with Yellow tracer

Bl/G : Blue with Green tracer W/B : White with Black tracer

Bl/W : Blue with White tracer W/R : White with Red tracer

Bl/Y : Blue with Yellow tracer Y/G : Yellow with Green tracer

Br/Y : Brown with Yellow tracer Y/R : Yellow with Red tracer

G/Y : Green with Yellow tracer Y/W : Yellow with White tracer

O/B : Orange with Black tracer

GENERAL INFORMATION 1-1

1

GENERAL INFORMATION

CONTENTS

WARNING/CAUTION/NOTICE/NOTE ......................................................... 1- 2

GENERAL PRECAUTIONS ......................................................................... 1- 2

SUZUKI GW250L3 (’13-MODEL) ................................................................ 1- 4

SERIAL NUMBER LOCATION .................................................................... 1- 4

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION...................... 1- 5

FUEL...................................................................................................... 1- 5

ENGINE OIL .......................................................................................... 1- 5

BRAKE FLUID....................................................................................... 1- 6

FRONT FORK OIL................................................................................. 1- 6

ENGINE COOLANT RECOMMENDATION .......................................... 1- 6

BREAK-IN PROCEDURES.......................................................................... 1- 7

CYLINDER IDENTIFICATION...................................................................... 1- 7

INFORMATION LABELS............................................................................. 1- 8

SPECIFICATIONS........................................................................................ 1- 9

DIMENSIONS AND CURB MASS......................................................... 1- 9

ENGINE ................................................................................................. 1- 9

DRIVE TRAIN ........................................................................................ 1- 9

CHASSIS ............................................................................................... 1-10

ELECTRICAL ........................................................................................ 1-10

CAPACITIES ......................................................................................... 1-10

COUNTRY AND AREA CODES

The following codes stand for the applicable country(-ies) and area(-s).

CODE COUNTRY or AREA EFFECTIVE FRAME NO.

P-12 Indonesia LC6GJ55B0C1 100001 –

P-21 E.U. LC6DC111101 100001 –

P-24 Australia LC6DC111201 100001 –

P-71 Mexico LC6GJ55E D1 100001 –

1-2 GENERAL INFORMATION

WARNING/CAUTION/NOTICE/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol

and the words WARNING, CAUTION, NOTICE and NOTE have special meanings. Pay special attention to

the messages highlighted by these signal words.



Indicates a potential hazard that could result in death or injury.



Indicates a potential hazard that could result in motorcycle damage.

Indicates a potential hazard that could result in motorcycle or equipment damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all

potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN-

INGS, CAUTIONS and NOTICES stated, you must use good judgement and basic mechanical safety princi-

ples. If you are unsure about how to perform a particular service operation, ask a more experienced

mechanic for advice.

GENERAL PRECAUTIONS



* Proper service and repair procedures are important for the safety of the service mechanic and

the safety and reliability of the motorcycle.

* When 2 or more persons work together, pay attention to the safety of each other.

* When it is necessary to run the engine indoors, make sure that exhaust gas is forced out-

doors.

* When working with toxic or flammable materials, make sure that the area you work in is well-

ventilated and that you follow all of the material manufacturer’s instructions.

* To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system

until they have cooled.

GENERAL INFORMATION 1-3

* Never use gasoline as a cleaning solvent.

* After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings

related to the system for leaks.

* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva-

lent.

* When removing parts that are to be reused, keep them arranged in an orderly manner so that

they may be reinstalled in the proper order and orientation.

* Be sure to use special tools when instructed.

* Make sure that all parts used in reassembly are clean. Lubricate them when specified.

* Use the specified lubricant, bond, or sealant.

* When removing the battery, disconnect the negative cable first and then the positive cable.

* When reconnecting the battery, connect the positive cable first and then the negative cable,

and replace the terminal cover on the positive terminal.

* When performing service to electrical parts, if the service procedures do not require use of

battery power, disconnect the negative cable from the battery.

* When tightening the cylinder head or case bolts and nuts, tighten the larger sizes first.

Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci-

fied tightening torque.

* Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking

nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with

new ones. Also, before installing these new parts, be sure to remove any left over material

from the mating surfaces.

* Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger

than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is

completely seated in its groove and securely fitted.

* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a

thread is smeared with them.

* After reassembling, check parts for tightness and proper operation.

* To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and

other fluids: batteries and tires.

* To protect Earth’s natural resources, properly dispose of used motorcycle and parts.

1-4 GENERAL INFORMATION

SUZUKI GW250L3 (’13-MODEL)

NOTE:

Difference between illustration and actual motorcycle may exist depending on the markets.

SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the

steering head pipe. The engine serial number 2 is located on the left side of the crankcase. These numbers

are required especially for registering the machine and ordering spare parts.

RIGHT SIDE

LEFT SIDE

GENERAL INFORMATION 1-5

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION

FUEL

Gasoline used should be graded 91 octane (Research Method) or higher. Unleaded gasoline is recom-

mended.

ENGINE OIL

Oil quality is a major contributor to your engine’s performance

and life. Always select good quality engine oil.

Use oil with an API (American Petroleum Institute) classification of

SG or higher with a JASO classification of MA.

Suzuki recommends the use of SAE 10W-40 engine oil. If SAE

10W-40 engine oil is not available, select an alternative according

to the right chart.

Suzuki does not recommend the use of “ENERGY CONSERV-

ING” and “RESOURCE CONSERVING” oils.

SAE API JASO

10W-40 SG or higher MA

E

N

E

R

G

Y

C

O

N

S

E

R

V

I

N

G

A

P

I

S

E

R

V

I

C

E

S

J

SAE

10W-40

A

P

I

S

E

R

V

I

C

E

S

J

SAE

10W-40

No recommendRecommend

SAE

10W-40

A

P

I

S

E

R

V

I

C

E

S

N

R

E

S

O

U

R

C

E

C

O

N

S

E

R

V

I

N

G

No recommend

“Donut” without “ENERGY CONSERVING”

nor “RESOURCE CONSERVING”

“Donut” with “RESOURCE CONSERVING” “Donut” with “ENERGY CONSERVING”

1-6 GENERAL INFORMATION

BRAKE FLUID

Specification and classification: DOT 4



FRONT FORK OIL

Use SUZUKI FORK OIL G10 or equivalent.

ENGINE COOLANT RECOMMENDATION

RECOMMENDED ENGINE COOLANT

The factory filled engine coolant of this vehicle is SUZUKI super long life coolant (Blue). It is recommended

to use this SUZUKI super long life coolant when replenishing or charging the engine coolant.

SUZUKI super long life coolant (Blue) as supply part is already diluted to the 50 percentage with deionized

water. Use it as it is without diluting.

SUZUKI recommends to use following coolants in that order.

1)

SUZUKI super long life coolant (Blue)

2) SUZUKI long life coolant (Green) or equivalent

ENGINE COOLANT

Use an anti-freeze/engine coolant compatible with an aluminum radiator.

There are two types of engine coolant: one used after diluting with distilled water and the other used as it is

(without diluting). SUZUKI super long life coolant is the latter type and SUZUKI long life coolant is the former

type.

WATER FOR MIXING

Use distilled water only. Water other than distilled water can corrode and clog the aluminum radiator.

ANTI-FREEZE/ENGINE COOLANT

The engine coolant performs as a corrosion and rust inhibitor as well as anti-freeze. Therefore, the engine

coolant should be used at all times even though the atmospheric temperature in your area does not go down

to freezing point.

LIQUID AMOUNT OF WATER/ENGINE COOLANT

Solution capacity (total): Approx. 1 350 ml (1.4/1.2 US/Imp qt)

For engine coolant mixture information, refer to cooling system section in page 7-2.

Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manu-

facturer, do not use or mix different types of fluid such as silicone-based and petroleum-based

fluid for refilling the system, otherwise serious damage will result.

Do not use any brake fluid taken from old or used or unsealed containers.

Never re-use brake fluid left over from a previous servicing, which has been stored for a long

period.

GENERAL INFORMATION 1-7

BREAK-IN PROCEDURES

During manufacture only the best possible materials are used and all machined parts are finished to a very

high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine

to maximum stresses. The future performance and reliability of the engine depends on the care and restraint

exercised during its early life. The general rules are as follows.

• Keep to these break-in engine speed limits:

Initial 800 km ( 500 miles): Below 5 500 r/min

Up to 1 600 km (1 000 miles): Below 8 250 r/min

Over to 1 600 km (1 000 miles): Below 11 000 r/min

• Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throt-

tle operation.

However, do not exceed 11 000 r/min at any time.

CYLINDER IDENTIFICATION

The two cylinders of this engine are identified as #1 and #2 cylinder, as counted from left to right (as viewed

by the rider on the seat).

#2

#1

1-8 GENERAL INFORMATION

INFORMATION LABELS

NO. LABEL or PLATE NAME

1 I.D. Plate (For-P21, 24, 71)

2 Tire information label

3 General warning label

4 Brake Approval Label (For-P21, 24)

5 Fuel limitation label (For-P12)

6 Noise label (For-P24)

Chain case

Frame (RH)

GENERAL INFORMATION 1-9

SPECIFICATIONS

DIMENSIONS AND CURB MASS

Overall length .......................................................................... 2 145 mm (84.4 in)

Overall width ........................................................................... 760 mm (29.9 in)

Overall height .......................................................................... 1 075 mm (42.3 in)

Wheelbase .............................................................................. 1 430 mm (56.3 in)

Ground clearance.................................................................... 165 mm (6.4 in)

Seat height .............................................................................. 780 mm (30.7 in)

Curb mass............................................................................... 183 kg (403 lbs)

ENGINE

Type ........................................................................................ Four stroke, liquid-cooled, SOHC

Number of cylinders ................................................................ 2

Bore......................................................................................... 53.5 mm (2.106 in)

Stroke...................................................................................... 55.2 mm (2.173 in)

Displacement .......................................................................... 248 cm³ (15.1 cu. in)

Compression ratio ................................................................... 11.5 : 1

Fuel system............................................................................. Fuel injection

Air cleaner ............................................................................... Non-woven fabric element

Starter system ......................................................................... Electric

Lubrication system .................................................................. Wet sump

Idle speed................................................................................ 1 400 ± 100 r/min

DRIVE TRAIN

Clutch ...................................................................................... Wet multi-plate type

Transmission........................................................................... 6-speed constant mesh

Gearshift pattern ..................................................................... 1-down, 5-up

Primary reduction ratio ............................................................ 3.238 (68/21)

Gear ratios, Low .................................................................... 2.417 (29/12)

2nd..................................................................... 1.529 (26/17)

3rd...................................................................... 1.182 (26/22)

4th...................................................................... 1.043 (24/23)

5th...................................................................... 0.909 (20/22)

Top..................................................................... 0.808 (21/26)

Final reduction ratio................................................................. 3.286 (46/14)

Drive chain .............................................................................. DID520VF, 116 links

1-10 GENERAL INFORMATION

CHASSIS

Front suspension .................................................................... Telescopic, coil spring, oil damped

Rear suspension ..................................................................... Swingarm type, coil spring, oil damped

Front fork stroke...................................................................... 120 mm (4.7 in)

Rear wheel travel.................................................................... 125 mm (4.9 in)

Steering angle......................................................................... 40°

Caster ..................................................................................... 26°

Trail......................................................................................... 105 mm (4.13 in)

Turning radius......................................................................... 2.5 m (8.2 ft)

Front brake.............................................................................. Disc brake

Rear brake .............................................................................. Disc brake

Front tire size .......................................................................... 110/80-17 M/C 57H, tubeless

Rear tire size........................................................................... 140/70-17 M/C 66H, tubeless

ELECTRICAL

Ignition type............................................................................. Electronic ignition (Transistorized)

Ignition timing.......................................................................... 10° CA B.T.D.C.at 1 400 r/min

Spark plug............................................................................... NGK CR7E or DENSO U22ESR-N

Battery..................................................................................... 12 V 36.0 kC (8 Ah)/10 HR

Generator................................................................................ Three-phase A.C. generator

Main fuse ................................................................................ 30 A

Fuse........................................................................................ 10/10/10/15 A

Headlight................................................................................. 12 V 60/55 W

Position light............................................................................ 12 V 5 W × 2

Turn signal light....................................................................... 12 V 10 W

License plate light ................................................................... 12 V 5 W

Brake/Tail light ........................................................................ 12 V 21/5 W

Combination meter light .......................................................... LED

Neutral indicator light .............................................................. LED

High beam indicator light ........................................................ LED

Turn signal indicator light ........................................................ LED

Oil pressure/Coolant temperature/Fuel injection warning light

.... LED

Engine rpm indicator light ....................................................... LED

CAPACITIES

Fuel tank, including reserve.................................................... 13.3 L (3.5/2.9 US/lmp gal)

Engine oil, oil change ............................................................. 2 100 ml (2.2/1.8 US/Imp qt)

with filter change .................................................. 2 400 ml (2.5/2.1 US/lmp qt)

overhaul................................................................ 2 400 ml (2.5/2.1 US/lmp qt)

Coolant.................................................................................... 1 350 ml (1.4/1.2 US/lmp qt)

These specifications are subject to change without notice.

PERIODIC MAINTENANCE 2-1

2

PERIODIC MAINTENANCE

CONTENTS

PERIODIC MAINTENANCE SCHEDULE .................................................... 2- 2

PERIODIC MAINTENANCE CHART..................................................... 2- 2

LUBRICATION POINTS ........................................................................ 2- 3

MAINTENANCE AND TUNE-UP PROCEDURES ....................................... 2- 4

AIR CLEANER....................................................................................... 2- 4

EXHAUST PIPE BOLTS AND MUFFLER BOLTS ............................... 2- 5

SPARK PLUGS ..................................................................................... 2- 6

VALVE CLEARANCE............................................................................ 2- 8

ENGINE OIL AND OIL FILTER ............................................................. 2-11

FUEL LINE............................................................................................. 2-12

PAIR (AIR SUPPLY) SYSTEM.............................................................. 2-13

THROTTLE CABLE PLAY .................................................................... 2-13

ENGINE IDLE SPEED ........................................................................... 2-13

CLUTCH CABLE PLAY ........................................................................ 2-14

COOLING SYSTEM............................................................................... 2-15

DRIVE CHAIN........................................................................................ 2-17

BRAKE .................................................................................................. 2-19

TIRES..................................................................................................... 2-23

STEERING............................................................................................. 2-24

FRONT FORKS ..................................................................................... 2-24

REAR SUSPENSION ............................................................................ 2-24

CHASSIS BOLTS AND NUTS .............................................................. 2-25

COMPRESSION PRESSURE CHECK ........................................................ 2-27

COMPRESSION TEST PROCEDURE .................................................. 2-27

OIL PRESSURE CHECK ............................................................................. 2-28

SDS CHECK................................................................................................. 2-29

2-2 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary to keep

the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome-

ters, miles and time for your convenience.

NOTE:

More frequent servicing may be required on motorcycles that are used under severe conditions.

PERIODIC MAINTENANCE CHART

NOTE:

I = Inspect and clean, adjust, replace or lubricate as necessary, R = Replace, T = Tighten

Interval

km

1 000 5 000 10 000 15 000

miles

600 3 000 6 000 9 000

Item

months

3 153045

Air cleaner element ---- I I R

Exhaust pipe bolts and muffler bolts T ---- T ----

Valve clearance I I I I

Spark plugs ---- I R I

Fuel line ---- I I I

Engine oil R R R R

Engine oil filter R ---- R ----

Throttle cable play I I I I

Idle speed I I I I

PAIR (air supply) system ---- I ---- I

Engine coolant

SUZUKI SUPER LONG LIFE

COOLANT (Blue)

Replace every 16 000 km (9 600 miles) or 48 months.

SUZUKI LONG LIFE COOLANT

(Green) or other than SUZUKI

SUPER LONG LIFE COOLANT

(Blue)

Replace every 8 000 km (5 000 miles) or 24 months.

Radiator hoses ---- I I I

Clutch cable play I I I I

Drive chain

IIII

Clean and lubricate every 1 000 km (600 miles).

Brakes IIII

Brake fluid

---- I I I

Replace every 2 years.

Brake hoses

---- I I I

Replace every 4 years.

Tires ---- I I I

Steer ing I ---- I ----

Front forks ---- ---- I ----

Rear suspension ---- ---- I ----

Chassis bolts and nuts T T T T

PERIODIC MAINTENANCE 2-3

LUBRICATION POINTS

Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.

Major lubrication points are indicated below.

NOTE:

* Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.

* Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the motorcycle

has been operated under wet or rainy conditions.

1 Clutch lever pivot 5 Drive chain

2 Side-stand pivot and spring hook 6 Brake lever pivot

3 Gearshift lever pivot and front footrest pivot 7 Brake pedal pivot and front footrest pivot

4 Center stand pivot and spring hook (For P12) 8 Pillion footrest

2-4 PERIODIC MAINTENANCE

MAINTENANCE AND TUNE-UP

PROCEDURES

This section describes the servicing procedures for each item of

the Periodic Maintenance requirements.

AIR CLEANER

• Remove the fuel tank. (5-2)

• Remove the screws 1 and slide the air cleaner cover 2

upward.

• Remove the air cleaner element 3.

• Carefully use air hose to blow the dust from the cleaner ele-

ment.

NOTE:

Always use air pressure on the throttle body side of the air

cleaner element. If air pressure is used on the other side, dirt will

be forced into the pores of the air cleaner element thus restrict-

ing air flow through the air cleaner element.

• Install the cleaned element or new air cleaner element in the

reverse order of removal.

NOTE:

If driving under dusty conditions, clean the air cleaner element

more frequently. Make sure that the air cleaner is in good condi-

tion at all times. The life of the engine depends largely on this

component.

DRAIN PLUG

• Remove the left frame cover. (8-4)

• Drain water by removing the drain plug 1.

Inspect every 5 000 km (3 000 miles, 15 months).

Replace every 15 000 km (9 000 miles, 45 months).

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